Insulating unit for curtain wall



June 11,1963 D. J. DOEDE INSULATING UNIT FOR CURTAIN WALL Filed July 13,1960 United States Patent 3,093,217 WSULATING UNIT FOR CURTAIN WALLDonald J. Beetle, Wausau, Wis, assignor to Marmet Gorporation, Wausau,Wis, a corporation of Wisconsin Filed July 13, 196i Ser. No. 42,627flaims. (Cl. 183-34) This invention relates to curtain wall constructionand more particularly to a prefabricated insulation unit for a metalwindow enclosure.

With the advent of metal construction used in curtain wall and othermetal Window enclosures problems of heat conduction have arisen. The useof aluminum for the metal frames allows a greater transfer of heatbetween wall elements than heretofore took place in previous buildingwall construction. Accordingly, an insulation problem is presented, andalthough prior art attempts have been made to solve this insulationproblem, none have been entirely successful. In one case a laminatedinsulating strip has been attempted, but this strip was assembled on thejob site with considerable diificulty and was found to lack in permanentinstallation due to deterioration.

It is an object of the present invention to provide an insulatingconstruction in a metal window enclosure that can be prefabricated withthe window assembly, is simply installed, inexpensive and efficient ininsulating qualities.

It is another object of the present invention to provide an insulatingconstruction in a metal window enclosure that will prevent condensationforming on the metal walls before it forms on the glass enclosure.

It is a further object of the present invention to provide an insulationconstruction for a metal wall enclosure that will prevent metal to metalcontact between the inside and outside walls and provide a permanentinsulation installation.

It is still another object of the present invention to provide aninsulating barrier for a metal window enclosure that is formed fromthermosetting plastic that is preassembled with the window frame and isnot visible in the completed installation.

It is a further object of the present invention to provide an insulatingconstruction in a metal window enclosure that upon installation retainsthe beauty and structural stability of conventional curtain wallconstruction.

In order that this invention may be fully understood, the followingdrawings are provided in which:

FIG. 1 is a view in elevation of a curtain wall on a building;

FIG. 2 is a sectional view taken on line IIII of FIG. 1;

FIG. 3 is an enlarged cross sectional View of that part of FIG. 2 wherethe Window and insulated panel are joined;

FIG. 4 is a cross-sectional view showing the details of assembly of theinsulating plastic barrier;

FIG. 5 is a vie-w in perspective of the metal clip used to fasten theinsulating plastic barrier in place; and

FIG. 6 is a view similar to FIG. 4 showing a modification of thefastening means for the insulating plastic barrier.

Referring to the drawings a conventional curtain wall construction isshown in FIGS. 1 and 2. Curtain wall as referred to herein includes thecomplete sidewall enclosure of a building excluding the buildingsupporting elements, and as illustrated shows vertically alternatinginsulated panels 10 and glazing means or glass windows 11. Brickwork 12may also be used on the surface, but it is to be understood that theinvention is not to be limited to any specific building construction,but refers to any curtain wall having metal window enclosures.

In FIG. 2 a cross-section view of the curtain wall shows the junction 13between insulated panel 10 and window 11, and this junction will be"described in detail in connection with FIG. 3. The mulli-on or frame 14surrounds the window, and the masonry wall is represented by the numeral16. A closure wall 18 separates the curtain wall from heating uni-ts 19having heating coils 21. Concrete flooring 23 has set thereon the basemoulding 22, and below flooring 23 is a ceiling joist 24 with parts 26,27, 28 and 29 representing a suspended ceiling.

The junction 13 connects window 11 and panel 10 through a plurality ofaluminum parts and at least one insulating element. In the particularembodiment shown three insulating elements 36, 37 and 38 are shown witha variation in size, but it should be understood that more or less thanthree insulating elements may be used, and they may all be of the sameor different size. Window 111 is shown as a single pane, but it may alsobe a conventional double window construction having an insulating spacetherebetween. In the assembly illustrated parts 43 and 44 are made ofextruded aluminum with part 43 being the outer part exposed to the areaoutside of the building and part 44 is the inner part exposed to theinside of the building. Since aluminum parts necessarily transfer heatreadily, the invention is seen to be embodied in the assembly comprisinga thermo-sett-ing plastic barrier 36 placed between parts 43 and 44 toprevent metal to metal contact. A snap-on glazing bead 42 is made ofextruded aluminum and fits in place on the top of part 43 and cooperateswith an upwardly projecting portion of part 44 to horizontally positionwindow 11. Conventional supports not shown vertically position window 11and conventional glazing materials 39 and 41 are used to fit and sealthe window.

Plastic barrier 36 and its fastening means are more clearly shown inFIGS. 4 and 5. Plastic barrier 36 is formed from rigid thermo-settingplastic material having a low coefiicient of 'heat transfer and is shownin the FIG. 4 embodiment with notches 45 formed adjacent its transverseends. Although plastic barrier 36 is shown as having a particularcross-sectional configuration, it is understood that the plastic barrier36 is not to be limited to any particular cross-sectional shape as longas notches 45 are formed adjacent the ends. However, as shown in theFIG. 6 embodiment, these notches are not essential if diiferentfastening means are used.

The ends of plastic barrier 36 are mounted in outer part 43 and innerpart 44 with clamping means 46 which comprises a U-shaped metal clip.The legs of the U are angled slightly outward from the center andinclude a plurality of tabs 47 formed by bending small sections of themetal inwardly along the legs of the U. For receiving the plasticbarrier 36' and clips '46 it will be seen from FIG. 4 that part 43 hasrecessed sections 34 and 35, and part 44 has recessed sections 32 and33. It should be noticed in FIG. 4 that there is no direct contactbetween plastic barrier 36 and parts 43 and 4-4- when they areassembled, and spaces 30 and 31 are provided to prevent such contactbetween the shank of plastic barrier 36 and the ends of parts 43 and 44.This spacing aids assembly and fitting.

One of the important advantages of this invention is that the assemblyof the entire insulating unit can be prefabricated at the factoryinstead of at the job installation area as done previously. The assemblycan be done in a jig holding parts 43 and 44 while the clips 46, whichpreferably are stainless steel, are placed in the race or recesses 32,33, 34 and 35. Next the plastic barrier 36, which extends continuouslybeneath the window, is

forced into the same recessed area. The rigid thermosetting plasticmaterial of barrier 36 forces the tabs 47 of clips 46 open until theyslip into notches 45 whereupon the plastic barrier 36 is locked in placeso that the aluminum parts 43 and 44, steel clips 46 and plastic barrier36 become an integral permanently locked unit. This prefabricated unitcan then be easily handled for final installation at the job siteinstead of having to do all such fitting on the job.

It will be seen that when glazing insert 42 is snapped in place thatplastic barrier 36 is completely hidden so that the beauty of thecurtain wall is maintained and the thermal efficiency improved sincethere is no metal to metal contact between the inside and outside walls.The insulated assembly will prevent condensation forming on the exteriorof the aluminum frame to a point where condensation will form on theglass 11 before it forms on the exterior aluminum.

It will be seen from FIG. 3 that when the plastic barrier 36 is inplace, it is spaced a substantial distance from the window 11, and thecross-sectional, longitudinal center line of window 11 passes generallythrough the inside end area of the plastic barrier.

The junction 13 further includes the mullion or outside frame parts 43and 49 that are interlocked to support part 43 which in assembly is thewindow sash. Parts 53 and 54 form the inside frame, and parts 51 and 52are sash inserts against which the sash closes to give a water tightcurtain wall. Weatherstrip 53 is provided of vinyl, and if desired, asecond Weatherstrip on the inside frame can be provided for doubleprotection.

Between outside frame parts 43 and 49 and inside frame parts 53 and 54are positioned additional thermosetting plastic barriers 37 and 38.These plastic barriers are mounted in the same manner as describedpreviously for plastic barrier 36 and as shown in FIG. 4. Similarly theframe unit 48, 49, 53 and 54 along with plastic barriers 37 and 38 canbe preassembled at the factory as previously described in connectionwith plastic barrier 36, and this preassembly affords the sameadvantages mentioned hereinbefore. Accordingly, it will not be necessaryto describe again the details of the insulating unit and its assembly.

Outside part 56 is a downwardly projecting glazing bead similar to part42, and part 56 cooperates with inside part 54 to contain insulatingpanel therebetween, which is supported in a conventional manner, notshown. Glazing materials 57 and 57' are used on the sides of panel 10for fitting. Panel 10 is seen to comprise an inside face 61 and anoutside face 62 turned over at their top to overlap and be separated bya vinyl gasket 63. Fastening means such as steel screws, not shown, holdthe faces together and the hollow central portion is filled withinsulating material such as fiber glass 64. It will be seen from FIG. 3that the cross-sectional longitudinal center line of panel 10 passesgenerally through the outside end area of the plastic barriers 36, 37and 38.

A modification of the fastening means for the plastic barriers 36, 37and 38 is shown in FIG. 6 in which the steel clips 46 are not required.The embodiment will be described for the parts 43 and 44 although it isunderstood this form of the fastening means can be used with all theplastic barriers placed in the curtain wall. In FIG. 6 the plasticbarriers are illustrated by barrier 71 which has an unchangingcross-sectional dimension. A recess 72 is formed in part 43 and a recess73 is formed in part 44 to receive the plastic barrier 71. It is seenthat the transverse dimension of the recesses is larger than thetransverse dimension of the barrier and the longitudinal walls of therecesses include serrations 74 and 75 in parts 43 and 44, respectively.Part 43, which is shown in this embodiment as the outside part holdingthe plastic barrier, includes a backing portion 76 so that a spacing 77can be formed between the end of plastic barrier 71 and portion 76. Inpart 44 a spacing 78 is formed by recess 73. In the recesses 71 and 72an adhesive is placed to coat the recesses, fill the serrations 74, 75and the spacings i7, 78 so that a locking bond is formed between theplastic barrier 71 and parts 43 and 44 when plastic barrier 71 is placedwithin the adhesive. All the assembled parts are then positioned in ajig until the adhesive sets. It will be seen that the adhesive forms acomplete layer around all confines of recesses 72 and 73 so that thereis no direct contact between insulator 71 and parts 43 and 44, and theassembled unit can then be taken to the job site for installation asdescribed in connection with FIGS. 3 and 4.

The particular embodiments of the invention illustrated and describedare to be considered illustrative only. The present invention includessuch other modifications and equivalents as may readily occur to thoseskilled in the art, within the scope of the appended claims.

It is claimed and desired to secure by Letters Patent:

1. A metal curtain wall on a building having an inner metal part formingpart of the inside wall of the building, an outer metal part spaced fromsaid inner part and forming part of the outer wall of the building, awindow positioned between the walls in fixed relation relative thereto,an insulated panel spaced from said window and forming part of saidouter wall, said inner and outer parts each having an element receivingarea formed therein in facing relation to each other, a rigid plasticinsulating element longitudinally positioned with one end within saidinner element receiving area and the other end positioned within saidouter element receiving area, all parts of the outside surface of saidinsulating element being spaced a predetermined distance from the edgesurfaces of said element receiving areas so that an insulating space isformed therebetween, fastening means located in said space for attachingsaid insulating element to said surfaces of said receiving areas, thecross-sectional center line of said window passing through the innerelement receiving area and the cross-sectional center line of saidinsulated panel passing through said outer element receiving area, saidinsulating element being positioned between and spaced from the adjacentends of said window and insulating panel.

2. A pre-fabricated aluminum curtain wall on a building having an inneraluminum part forming a part of the inside wall of the building, anouter aluminum part spaced from said inner part and forming part of theouter wall of the building, a window being positioned between said wallsin fixed relation relative thereto, an insulated aluminum panel spacedfrom said window and forming part of said outer wall, said inner andouter parts each having an element receiving area formed therein infacing relation to each other, a rigid thermo-setting plastic insulatingelement longitudinally positioned with one end within said inner elementreceiving area and the other end positioned within said outer elementreceiving area, all parts of the outside surface of said insulatingelement being spaced a predetermined distance from the edge surfaces ofsaid element receiving areas so that an insulating space is formedtherebetween, a U-shaped clamping means mounted in each elementreceiving area and extending around each end of said insulating elementin abutting relation, said clamping means including integral tabspartially cut out from the side walls thereof to project inwardly forpositioning in locking relation with notches formed in said insulatingelement, the cross-sectional center line of said window passing throughthe inner element receiving area and the cross-sectional center line ofsaid insulated panel passing through said outer element receiving area,said insulating element being positioned between and spaced from theadjacent ends of said window and insulating panel.

3. A pie-fabricated aluminum curtain wall on a building having an inneraluminum part forming a part of the inside wall of the building, anouter aluminum part spaced from said inner part and forming part of theouter wall of the building, a window being positioned between said Wallsin fixed relation relative thereto, an insulated aluminum panel spacedfrom said window and forming part of said outer wall, said inner andouter parts each having an element receiving area formed therein infacing relation to each other, a rigid thermo-setting plastic insulatingelement longitudinally positioned with one end within said inner elementreceiving area and the other end positioned within said outer elementreceiving area, all parts of the outside surface of said insulatingelement being spaced a predetermined distance from the edge surfaces ofsaid element receiving areas so that an insulating space is formedtherebetween, an adhesive bonding layer being deposited in each elementreceiving area and extending around the ends of said insulating elementto fill said insulating space between the outer surface of theinsulating element and the edge surfaces of said element receivingareas, the cross-sectional center line of said window passing throughthe inner element receiving area and the cross-sectional center line ofsaid insulated panel passing through said outer element receiving area,said insulating element being positioned between and spaced from theadjacent ends of said window and insulating panel.

4. A pre-fabricated aluminum curtain wall on a building having an inneraluminum part forming a part of the inside Wall of the building, anouter aluminum pant spaced from said inner part and forming part of theouter wall of the building, a window being positioned between said Wallsin fixed relation relative thereto, an insulated aluminum panel spacedfrom said window and forming part of said outer Wall, said inner andouter parts each having an element receiving area formed therein infacing relation to each other, a rigid thermo-setting plastic insulatingelement longitudinally positioned with one end within said inner elementreceiving area and the other end positioned within said outer elementreceiving area, all parts of the outside surface of said insulatingelement being spaced a predetermined distance from the edge surfaces ofsaid element receiving areas so that an insulating space is formedtherebetween, said element receiving areas being U-shaped and havingserrations formed on said edge surfaces thereof, and adhesive bondinglayer being deposited in each element receiving area and extendingaround the ends of said insulating element to fill said serrations andsaid insulating space between, the crosssectional center line of saidwindow passing through the inner element receiving area and thecross-sectional center line of said insulated panel passing through saidouter element receiving area, said insulating element being positionedbetween and spaced from the adjacent ends of said window and insulatingpanel.

5. A pre-fabricated aluminum curtain wall on a building having a firstinner aluminum part having an upwardly projecting portion forming a partof the inside wall of the building, a first outer aluminum partdissimilar and spaced from said first inner part and having a downwardlyprojecting portion forming a part of the outer wall of the building, awindow being positioned between said Walls in fixed relation relativethereto, said first inner and outer parts each having an elementreceiving area formed therein in facing relation to each other, a firstrigid thermo-setting plastic insulating element longitudinallypositioned with one end within said first inner element receiving areaand the other end within said first outer element receiving area, allparts of the outside surface of said first insulating element beingspaced a predetermined distance from the edge surfaces of said elementreceiving areas so that a first insulating space is formed therebetween,a second inner aluminum part with a downwardly projecting portionforming part of said inside wall, a second outer aluminum par-t havingan outwardly projecting portion forming part of said outside Wall, aninsulating aluminum panel spaced from said window and forming part ofsaid outer wall, said second inner and outer parts each having anelement receiving area formed therein in facing relation to each other,a second rigid thermo-setting insulating element longitudinallypositioned with one end within said second inner element receiving areaand the other end within said second outer element receiving area, allparts of the outside surface of said second insulating element beingspaced a predetermined distance from the edge surfaces of said elementreceiving area so that a second insulating space is formed therebetween,fastening means located in said first and second spaces for attachingsaid first and second insulating elements to said surfaces of said firstand second receiving areas, respectively, the cross-sectional centerline of said Window passing through the first and second inner elementreceiving areas and the cross-sectional center line of said insulatedpanel passing through said first and second outer element receivingareas, said first and second insulating elements positioned between andspaced from the adjacent ends of said window and insulated panel.

References Cited in the file of this patent UNITED STATES PATENTS2,035,476 Herwood Mar. 31, 1936 2,205,780 Forsthoefel June 25, 19402,835,360 Bernardoni May 20, 1958 2,914,145 Benson Nov. 24, 1959 FOREIGNPATENTS 768,499 Great Britain Feb. 20, 1957 804,258 Great Britain Nov.12, 1958

1. A METAL CURTAIN WALL ON A BUILDING HAVING AN INNER METAL PART FORMINGPART OF THE INSIDE WALL OF THE BUILDING, AN OUTER METAL PART SPACED FROMSAID INNER PART AND FORMING PART OF THE OUTER WALL OF THE BUILDING, AWINDOW POSITIONED BETWEEN THE WALLS IN FIXED RELATION RELATIVE THERETO,AN INSULATED PANEL SPACED FROM SAID WINDOW AND FORMING PART OF SAIDOUTER WALL, SAID INNER AND OUTER PARTS EACH HAVING AN ELEMENT RECEIVINGAREA FORMED THEREIN IN FACING RELATION TO EACH OTHER, A RIGID PLASTICINSULATING ELEMENT LONGITUDINALLY POSITIONED WITH ONE END WITHIN SAIDINNER ELEMENT RECEIVING AREA AND THE OTHER END POSITIONED WITHIN SAIDOUTER ELEMENT RECEIVING AREA, ALL PARTS OF THE OUTSIDE SURFACE OF SAIDINSULATING ELEMENT BEING SPACED A PREDETERMINED DISTANCE FROM THE EDGESURFACES OF SAID ELEMENT RECEIVING AREAS SO THAT AN INSULATING SPACE ISFORMED THEREBETWEEN, FASTENING MEANS LOCATED IN SAID SPACE FOR ATTACHINGSAID INSULATING ELEMENT TO SAID SURFACES OF SAID RECEIVING AREAS, THECROSS-SECTIONAL CENTER LINE OF SAID WINDOW PASSING THROUGH THE INNERELEMENT RECEIVING AREA AND THE CROSS-SECTIONAL CENTER LINE OF SAIDINSULATED PANEL PASSING THROUGH SAID OUTER ELEMENT RECEIVING AREA, SAIDINSULATING ELEMENT BEING POSITIONED BETWEEN AND SPACED FROM THE ADJACENTENDS OF SAID WINDOW AND INSULATING PANEL.